A few months ago I bought some flexible filament. It’s a first for me, because since I started 5 years ago, I’ve only used PLA.
That’s why, after a few test prints to find the right settings on Cura (software for cutting a 3D model). I challenged myself to make a shell for my cell phone.
I then thought about how I could start modeling it.
I thought I’d simply take the ribs of my phone and insert them into Fusion. Then I’d make a larger rectangle into which I’d extrude the 3D model of my phone.
Hull animation using method 1
But I soon realized that the result wasn’t what I’d hoped for.
So I turned to another method.
I drew a cross-section of my phone’s shell and then sweep along a path in the shape of my phone.
Cross-section of the hull and hull path
Problems begin…
Printing flexible filament is a complex task, with the birth of new problems. That’s why I advise you to use a printer with a Direct Drive extrusion system, rather than a Bowden extruder which, because of the distance between the nozzle and the extruder, will make printing more complicated, if not impossible. For this, there are kits available to upgrade your printer.
I have a Direct Drive system, but it’s not a foregone conclusion. The filament requires adjustments to the slicer, such as reducing the speed, increasing the temperature or deactivating the supports.
First impressions
My first impressions of the flexible went well for small parts, but printing a large volume like the hull was tougher.
The first layer wouldn’t print properly or would peel off, and the nozzle would clog up unexpectedly.
I had to go over it several times and adjust the level of my tray.
My first piece was a failure. The filament didn’t have time to cool down, so the edges of the hull were very poorly printed. What’s more, the thickness of the hull was too thin, making it too soft.
Result of the first hull
Second try, a step forward
My second try was quite conclusive: the thickness was good and allowed me to have a shell that held the phone well. Despite a few flaws (the print in the vacuum is not very clean), the case is still usable and seems robust.
My feedback after 4 months of use
I’ve been using the case on my phone on a daily basis for 4 months now. I’m very happy with it. The only drawback is that it gets dirty and loses some of its red color.
